stracener_emis 7305/5305_spr08_03.18.08 1 systems supportability analysis overview dr. jerrell t....
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Systems Supportability Analysis Overview
Dr. Jerrell T. Stracener, SAE Fellow
Leadership in Engineering
EMIS 7305/5305Systems Reliability, Supportability and Availability Analysis
Systems Engineering ProgramDepartment of Engineering Management, Information and Systems
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Supportability – DoD Definition
The degree to which system design characteristics and planned logistic resources, including manpower, meet system peacetime operational and wartime utilization requirements
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Supportability Elements
•Reliability
•Maintainability / LSA
•Testability
•Logistics Engineering
•Integrated Logistics Support
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Problem / Objective
•Problem
Too many / conflicting parameters to effectively influence weapon system and support system design
•Objective
Develop meaningful (relative to design) effectiveness / supportability figures of merit applicable to
weapon system & support system design influence
measurement of weapon system & support system effectiveness / supportability
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Benefits
•Provide rational quantitative basis for design decisions relative to effectiveness / supportability
-evaluate point designs
-evaluate impact of design changes
-evaluate design alternatives
-trade studies
-sensitivity analysis to identify drivers
•Figures of Merit which are
-meaningful to the Customer
-understandable by Management
-relevant to the Designer
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Approach
Develop Effectiveness / Supportability Figures of Merit
Develop Analysis / Measurement Capability Requirements
Develop Analysis / Measurement
Capabilities (Models)
Automate & Integrate with CAE / CAD
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Caution
•Supportability can be an all encompassing buzzword
•The “system” requirement is more than supportability
•A “system” is required to counter a threat therefore
-a system is designed to counter the threat
-not be supportable
-supportable is just one element
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Effectiveness / Supportability
Favorable Adverse
Equipment Architecture
Minimum Loss of Essential Functions Reliability Effectiveness Supportability
EquipmentDesign
Reduce failure & maintenance rates Reliability Effectiveness -
Equipment Access
Reduce time rqd to get to equipment Maintainability
Effectiveness / Supportability -
Equipment Location
Make high maintenance items easy to get to Maintainability
Effectivness /Supportability -
Low Observable
Reduce Radar Cross Lection
Reliability & Maintainability Effectiveness Supportability
Design Element
Impact
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Defense Acquisition ManagementDefense Acquisition ManagementDefense Acquisition Management
Funding:
•• Process entry points at Process entry points at Milestone A, B, or CMilestone A, B, or C
•• Entrance criteria met Entrance criteria met before entering phasebefore entering phase
•• Evolutionary Acquisition Evolutionary Acquisition or Single Step to Full or Single Step to Full CapabilityCapability
•• Conduct Conduct AoAAoA, refine , refine initial concept & initial concept & develop Technology develop Technology Development Development StrategyStrategy
ConceptRefinement
Full-Rate Prod &Deployment
•• Full rate Full rate productionproduction
•• Deployment of Deployment of systemsystem
Requirements:
System Integration
System Demo
System Dev & Demonstration
IOC
CriticalDesignReview
LRIP
Operations& Support
•• I ntegrate Integrate subsystems, subsystems, complete complete detailed design, detailed design, and reduce and reduce systemsystem--level level riskrisk
SystemIntegration
ConceptRefinement
TechnologyDevelopment
Concept Decision
FRP & Deployment
Production & Deployment
Low-Rate InitialProduction
•• Create Create efficient efficient manufacturinmanufacturing capabilityg capability
•• LRI PLRI P•• IOT&E, IOT&E,
LFT&E of LFT&E of prodprod--rep rep articlesarticles
C
Pre-Systems Acquisition Systems Acquisition Sustainment
User Needs & Technology Opportunities
(BA 1 & 2)
FOC
•• Complete Complete developmentdevelopment
•• Demonstrate ability Demonstrate ability of system to of system to operate in useful operate in useful way consistent with way consistent with KPPsKPPs
•• Combined DT/ OTCombined DT/ OT
SystemDemonstration
•• Reduce technology Reduce technology risk & determine the risk & determine the appropriate set of appropriate set of technologies to be technologies to be integrated into a full integrated into a full systemsystem
•• Demo the Demo the technologies in a technologies in a relevant environmentrelevant environment
Technology Development
BA 3/4 BA 5 BA 5/Procurement Proc/Operations & MaintenanceBA 5
CDD CPD
Validated & approved by operational validation authority
ICD
Increment II
Increment III
B DRR C FRP
B DRR C FRP
BA
FRPDecision Review
5 Year Cost To Own*5 Year Cost To Own*Source: Edmunds.com Source: Edmunds.com
0.680.741.360.480.40Cost/Mile
50,74755,397101,94536,17729,808**Total 5 Yr Cost
8188452,026795648Repairs
5,0325,5423,5243,2983,713Maintenance
14,64814,15311,8158,7127,411Fuel
1,8262,0754,6791,251937Taxes & Fees
4,0854,2057,6273,8653,764Insurance
5,33656,34815,4863,6192,547Financing
19,002(58%)22,229(61%)56,788(60%)14,637(67%)10,788(67%)Depreciation
$32,871$36,616$95,415$22,298$16,199Purchase Price
Pickup(Dodge 1500)
SUV(Chevrolet Tahoe)
Luxury Car(Jaguar XJ)
Large Car(Chevrolet Impala)
Medium Car(Ford Focus)
*Model year 2006 data**Based on 15,000 miles per year
Op
erat
ing
Co
st
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Supportability
Supt PlaningR,M & SLSAFlight Test
Config.MgmtProvisioning Tech Data
SparesSupt Equip
Training Sys Initial ContractorSupportTraining Prog Mgmt Field/
Base SuptTech Supt Serv
Depot Maint/ModsSpares Inven Mgmt
Engine/Comp Maint, Repair & Overhaul
Dsgn Influ & SuptSys Devlp
Support SystemProduction
Initial Support
Sustainment
Concept Development Production Post Prod. Retirement
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Supportability Requirements
Supportability design requirements evolve fromthe customer’s need, which is typically expressed in terms of system operationaleffectiveness
OperationalReliability
AvailabilityPerformance
Capability
OperationalEffectiveness
How well How Long How Often
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System Operational Parameters
Operational Effectiveness
• Readiness or Availability• Mission Success
Ownership Cost
• Logistic Support Cost• Operating Cost
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Availability (Operational Readiness)
“The Probability that at any point in time the system is either operating satisfactorily or ready to be placed in operation on demand when used under stated conditions.”
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Operational Availability (Ao):
Ao includes the impact of logistics on availability
- logistics elements included must be defined in advance
MDTMTTRMTBF
MTBFAo
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Availability Analysis Flow Diagram
• Mission Reliability
• MTBF
• MTBM
Reliability Analysis
Availability Analysis
• MTTRMaintainability
AnalysisCost Effectiveness
Analysis
• MDT (A)
• MDT (L)
Supportability Analysis
Life Cycle Cost
Analysis
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Reliability and Supportability
Requirements
Systems Operational Performance
ReliabilitySupportability
Effectivenessand Availability
Life Cycle Cost
Design
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Supportability Functions
• System Design Influence– Requirements Development– Design Input– Evaluation and Trade Analysis– Resource Identification– Test and Evaluation
• Development of Support Resources (Products)– Trained Personnel– Support Equipment– Supply Support
• Fielding and Customer/Product Support
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• Maintenance Planning• Manpower and Personnel• Materials Management• Support Equipment• Technical Data• Training and Training Support• Computer Resources Support• Facilities• Packaging, Handling, Storage and Tranportation• Design Interface• Physical Distribution
Elements of System Supportability
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The process conducted to evolve and establish maintenance concepts and requirements for the lifetime of the system.
Maintenance Planning
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Manpower and Personnel
The identification and acquisition personnel with the skills and grades required to operate and support the system over its lifetime.
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• All management actions, procedures, and techniques used to determine requirements to acquire, catalog, receive, store, transfer, issue and dispose.
• Includes provisioning for both initial support and replenishment supply support.
• Includes the acquisition of logistics support for support and test equipment:– Raw Material– In-Process Material– Finished Products and Spare Parts
Materials Management
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• All equipment (mobile or fixed) required to support the operation and maintenance of the system.
• Includes associated multi-use end items, ground handling and maintenance equipment, tools, metrology and calibration equipment, test equipment, and automatic test equipment.
Support Equipment
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• Scientific or technical information recorded in any form or related medium (such as manuals and drawings).
• Computer programs and related software are not technical data; documentation of computer programs and related software are.
• Excluded are financial data or other information related to contract administration.
Technical Data
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• the process, procedures, techniques, training devices, and equipment used to train personnel to operate and support the system. – Individual and crew training (both initial and
continuation) – new equipment training– Logistics support planning for training
equipment and training device acquisitions and installations
Training and Training Support
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• Permanent, semi-permanent or temporary real property required to support the system, including:
• conducting studies to define facilities or facility improvements
• locations, space needs, utilities, environmental requirements, real estate requirements and equipment requirements.
Facilities
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Resources, processes, procedures, design considerations and methods to ensure that all system, equipment, and support items are preserved, packaged, handled and transported properly, including:– environmental considerations– equipment preservation requirements for short
and long term storage– transportability.
Packaging, Handling, Storage and Transportation
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Relationship of logistics related design parameters to readiness and support resource requirements. – expressed in operational terms rather than as
inherent values – specifically relate to system readiness
objectives and support costs of the system.
Design Interface
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– Storage / Warehousing– Inventory Maintenance– Materials / Product Packaging & Handling– Transportation– Materials / Product Scheduling
Physical Distribution
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Some Other Elements of System Supportability
• Traffic and transportation• Warehousing and storage• Industrial packaging• Materials handling• Inventory control• Order processing• Customer service levels• Demand forecasting• Procurement• Distribution communications• Plant and warehouse locations• Return goods handling• Parts and service support• Salvage and scrap disposal
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Supportability in Product Development
• The primary thrust is two-fold
- Influence product design to ensure reliability, usability, safety, etc system
- Identify the resources to ensure supportability of the delivered product andcustomer support
• Supportability translates performance, user requirements and user experience into the operational, maintenance and support concepts
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Supportability in Product Development - continued
• Logistics design criteria and guidelines are provided to design
• As the schedule progresses, maintenance andsupport requirements (scheduled and unscheduled)are determined
• Requirements for support equipment, spare parts,publications, training, facilities, personnel and skillsare established
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Build-to-Package
Build-to-Package
Productdesign
Productionplanning
Qualityplanning
Tooldesign
Process
Logisticscharacteristics
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Build-to-Package
SupportabilityDefinition Package
Logisticsupportanalysis
Manpower,personneland skills
ProvisioningTraininganalysis
Technicalsupport
data
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Benefits of Design For Supportability
• System Characteristics
– Inherent Reliability– Easily Operable and Maintainable
• Support System Characteristics
– Adequate Supply of Trained Personnel– Minimal / Low Cost Support Equipment– Capitalize Existing Facilities– Transportable Design
• Achieves Goals in:
– Availability– Cost Effectiveness
Life Cycle Cost (LCC)Operating & Support (O&S) Cost
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Supportability During Design
Conceptual Initial FinalObjective:
Minimum DowntimeMinimum LCC
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Supportability During Conceptual Design
• A system’s design establishes the basic requirement for support resources
• Support is a design parameter• Support features must be included in the
conceptual design
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Support System design and Development Analysis
• Maintainability Analysis• Supply Chain Analysis• System PHM Analysis• Reliability Centered Maintenance Analysis (RCMA)• Level of Repair Analysis (LORA)
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Maintainability Objective
To design and develop systems and equipment which can be maintained in the least time, at the least cost, and with a minimum expenditure of support resources, without adversely affecting the item performance or safety characteristics
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Maintainability Metrics
• Times– MTTR : Mean Time to Repair– T5o% : Median Time to Repair– TMAX : Maximum Time to Repair
(usually 95th percentile– LDT : Logistics Delay Time– SDT : Supply Delay Time– MDT : Mean Down Time– DTM : Down Time for Maintenance– DTS : Down Time For Supply
• Events– MTBM : Mean Time Between Maintenance– MTTPM : Mean Time to Preventive Maintenance– MTBPM : Mean Time Between Preventive Maintenance
• Manpower– CS : Crew Size– MMH/FH : Man-hours per flight hour
• Diagnostics– FD : Fault Detection– FI : Fault Isolation– FA : False Alarms
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Basing Site
Depot/Warehouse Site
Manufacturing Site
Operational Unit
What is a Supply Chain?Parts and Information
LocalPart
Repair
DepotPart
Repair
Remanufacture
Product Use
Product Maintenance
LocalStock
Warehouse
Manufacture
InformationSystem
Good Parts DataBad
Dispose
Dispose
Dispose
Dispose
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Objectives Supply Chain Analysis
Structure of the Supply Chain: – “Optimal" numbers– Locationbased on considerations such as customer service requirements,
leadtimes, operational costs, and capacities. – Supply Uncertainty:
Relationship with suppliers Selection of suppliers
based on cost, flexibility in supply contracts, expected learning curves of suppliers, and agreements on cost and information sharing.
– Operational Policies: Inventory control policies Information-sharing strategies.
Analysis provides understanding of critical tradeoffs and alternatives in practical decision-making for a range of inter-related supply chain management issues:
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Prognostic Health Management Analysis
The purpose of Prognostic Health Management is to repair systems before they fail, while maximizing useful life consumption, and to have the necessary parts, tools and maintainers waiting nearby to resolve the correct problem as quickly and efficiently as possible.
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Supportability – How do you do it?
• ITS Objective: design for support– Consider each ILS functional element during design process
to minimize support– Develop clearly stated design objectives
• Design for support– Discard at failure
• Eliminating repair reduces support burden• Possible for small end items, not realistic for large
weapon systems• Repair versus discard quantifiable in terms of cost of item
versus cost of repair– Modular replacement
• Designing for discard would naturally include designing for modularity and modular replacement
• Optimize modules in terms of size, cost of components and functions
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Supportability – How do you do it? (cont)
• Design for support (Continued)– High reliability parts
• Reduce number of times item must be repaired– Bite/Integrated diagnostics/standard TMDE
• If it fails, bite is best mode to determine failure– Standard test points
• External test equipment– Accessibility
• If failure occurs design for ease of maintenance– Quick release fasteners
• Shorten R/R times– Standard parts
• Reduces numbers of different parts• Reduces numbers and types of tools
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Supportability – How do you do it? (Cont)
•Design for support (continued)
-Simplicity
•Reduce sheer number of components that comprise end item
-Lifting points for transportability
-Reduced Weight / Cube
-Soldier / Machine Interface
•Limitations of target audience
•ILS Objective: Design of Support
-Equal balance of performance and support objectives is logistician’s goal
-If performance objectives are met at expense of support objectives then design of support is critical
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Supportability – How do you do it? (Cont’d)
•Design of Support
-Reduce number of parts
•Lower cataloging, inventory and pipelines costs
-Reduce number of reparable
•Reduces number of types of maintenance actions
•Reduces attendant logistics tail (TOOLS, TMDE, TM PGS, ETC.)
-Reduction / consolidation of common tools / TMDE
•Simplifies maintenance actions
-Eliminate special tools, TMDE, and skill requirements
-Reduce manpower
-Reduce skill required
-Reduce training course lengths
-Increase modes of transportation
-Reduce number of TM pages
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Supportability – How do you do it (cont’d)
• How do you achieve the objectives?
– Early Planning via front-end LSA
– Sound ILS RFP/Contracts
– Comprehensive Program Reviews
– Logistics Testing
– Post Deployment Assessments
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Supportability – How do you do it? (cont’d)
• How do you measure achievement?
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Design for support scorecard
System name
System MTBFNumber of PartsNumber of ReparableNumber of Special ToolsNumber of Common ToolsNumber of PersonnelNumber of Different SkillsTransportation ModesNumber of TM pages..
Factor Baseline System New System
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WEAPON SYSTEM O&S